eloprog 485EPF.. - Vers. 1.2 eloprog Configurable safety system FIELD BUS MODULES

eloprog 485EPF.. - Vers. 1.2 eloprog Configurable safety system FIELD BUS MODULES 1

List of contents INTRODUCTION 3 ELECTRICAL CONNECTIONS 3 PROTOCOL DATA PACKAGE COMPOSITION 4 DIAGNOSTICS 6 The "I/O index" field 6 The "Diagnostics code" field 7 SIGNALS 8 EXAMPLES OF DIAGNOSTICS 12 Example 1 12 Example 2 12 Example 3 13 BUS CONFIGURATOR USER INTERFACE 14 Graphic interface 15 CONFIGURATION 16 Example of configuration 18 2

ELOPROG FIELD BUS MODULES INTRODUCTION This technical sheet describes the operation of the field bus modules of the eloprog series: 485EPFPD (PROFIBUS DP); 485EPFDN (DeviceNet); 485EPFCO (CANOpen); 485 EPFEC (EtherCat); 485EPFEI (EtherNet/IP); 485 EPFPN (PROFINET); 485EPFUB (USB) ELECTRICAL CONNECTIONS Each module is provided with four connectors (Figure 1): 1) 5 way connector MSC --> to the eloprog system 2) Micro USB connect --> to the PC 3) BUS connector --> to the field bus (not present on 485EPFUB) 4) Front terminal --> power supply TERMINAL BLOCK (SIDE A - TOP) TERMINAL SIGNAL 1 +24VDC + 20% 2-3 - 4 GND Table 1 + Install safety units in an enclosure with a protection class of at least IP54. + The supply voltage to the units must be 24VDC±20% (PELV, in compliance with the standard EN 60204-1). + Do not use eloprog to supply external devices. + The same ground connection (0VDC) must be used for all system components Figure 1 3

PROTOCOL DATA PACKAGE COMPOSITION The bus module exports the system status and the status and diagnostics elements of all I/Os configured on the eloprog and enables 8 single field bus inputs to be imported. The input and output memory maps are described in the tables at page 3. The input map is made up by a single byte representing the fieldbus inputs. The output map is made up by a status byte, a variable number of bytes for the Mosaic input status, a byte representing the copy of the fieldbus inputs, a variable number of bytes to represent the probes status, a variable number of bytes to represent the Mosaic OSSD status, two bytes to represent the Mosaic diagnostics. The system status is shown as 1 byte in which the 0 bit indicates whether the eloprog is online/offline and bit 1 indicates the presence of diagnostics elements. Each input and each output (OSSD) configured on the system is associated with two information elements: status and diagnostics. Status is a binary value, 0 or 1, diagnostics is a code indicating the condition of the I/O, which can be OK or indicate a problem on the I/O. Each module with inputs has a number of bits corresponding to the number of physical inputs which are present; thus the modules 485 EPB, 485 EPE08, 485EPE08A02 are associated with 1 byte (8 bit), the modules 485EPE16, 485EPE12 with 2 bytes (16 bit) for the inputs status. All safety outputs are summarized in 1 or 2 bytes. The location of the inputs varies according to the type of modules that are installed, in the following order: 485EPB, 485EPE08A02, 485EPE16, 485EPE08, 485EPE12. If several modules of the same type are installed the order follows the node number. Diagnostics elements are in the form of 2 bytes which indicate the number of the I/O with the problem and the value of the diagnostics element. If there is more than one diagnostics element, the relative values alternate every 500 ms. Each set of information: - input status, - input diagnostics, - field bus input status, - probe status, - safety output status, - safety output diagnostics can be enabled/disabled in order to control the information and thus the number of bytes exported to the field bus. The field bus inputs are 8 independent bits through which 8 different states can be injected into the electrical panel. The byte that represents the 8 field bus inputs is mapped as the first PLC input byte. For the fieldbuses in which the mapping position is mandatory (i.e. PROFIBUS DP) the input byte must be mapped before the output bytes. For the fieldbuses based on CANOpen the data can be accessed only via PDO. The SDO access is not supported. 4

The map of PLC input bytes is described in the table below: (1 byte) SYSTEM STATUS B0=1: Mosaic online / B1=1: Diagnostic(s) present Inputs Minimum: 1 byte Maximum: 16 byte Fieldbus input Probe OSSD Minimum: 1 byte Maximum: 2 bytes Number I/Os Diagnostic code DIAGNOSTICS (2 bytes) see: Table 4 - Table 5 - Table 6 The following table describes the input map of PLC: B7 B6 B5 B4 B3 B2 B1 B0 Fieldbus input è If the eloprog system includes a field bus module (485EPFPD, 485EPFCO oder 485EPFDN), the configuration software report will include a table with the I/O index for all the inputs, field bus inputs, probe and safety outputs in the electric circuit. 5

DIAGNOSTICS Each input and each safety output is associated with a relative diagnostic code. When the I/O is connected correctly the diagnostic code is OK and is not exported to the field bus; if there is a problem on the I/O, the system exports 2 bytes to the field bus with: - the index of the I/O in question - the relative diagnostics code The "I/O index" field This field indicates the number used to identify the I/O with a diagnostics code other than OK. Possible values for this field are shown in Table 2. TYPE OF SIGNAL Input 1-128 Output 192-255 Table 2 I/O INDEX 6

The "Diagnostics code" field The "Diagnostics code" field indicates the diagnostics for the I/O. Possible values for this field are shown in tables 3 and 4. 128 (0x80) Input diagnostics OK - Input diagnostics 1 Not moved from zero Both switches have to go to rest condition 2 Concurrent failed Both switches have to change state simultaneously 3 Concurrent failed hand1 Wrong connection on one side of a two-hands switch 4 Concurrent failed hand2 Wrong connection on one side of a two-hands switch 7 Switch inconsistent The selector should not have more than one input set 8 Switch disconnected The selector should have at least one input set 10 OUT_TEST error OUT_TEST diagnostics present on this input 11 Second input KO Redundancy check failed on input 12 OUT_TEST diagnostics OK 13 Output connected to other inputs Test output not connected to the right input 14 Output OK but input connected to 24VDC Stucked input 15 Short circuit between test photocell and input photocell Photocell response time too low 16 No response from photocell The test signal on the photocell emitter is not seen on the receiver 17 Short circuit between photocells The test signal is present on two different photocells 18 MAT disconnected Wrong mat connection 19 Output inconsistent with feedback The test signal on input is present on more than one OUT_TEST 20 Connection incorrect The test signal is present on more than one input 21 Output stuck The test signal on the input is not present on the OUT_TEST 22 Second OUT_TEST KO Redundancy check failed on OUT_TEST 133 (0x85) 1 TWO-HAND concurrent failed Two-hands switch has to change state simultaneously 134 (0x86) 2 Not started Start test failed 137 (0x89) 3 Waiting for restart The input has manual reset and has not been restarted Table 3 OSSD Diagnostics 0 OSSD DIAGNOSTICS OK 1 ENABLE MISSING 2 WAITING FOR RESTART OSSD 3 FEEDBACK K1/K2 MISSING 4 WAITING FOR OTHER MICRO Redundancy check failed on OSSD Table 4 è If there are diagnostics for more than one I/O, the I/O index and diagnostics code signals are sent in turn every 500ms. 1 The diagnostic 133, 134 and 137 do not provide visual error message on the LED of eloprog 2 The diagnostic 133, 134 and 137 do not provide visual error message on the LED of eloprog 3 The diagnostic 133, 134 and 137 do not provide visual error message on the LED of eloprog 7

SIGNALS eloprog eloprog eloprog eloprog eloprog eloprog eloprog 485 EPFCO 485 EPFDN 485EPFPD 485EPFEC 485EPFEI 485EPFPN 485EPFUB Figure 2 LED MEANING ON RUN IN FAIL EXT FAIL LED1 LED2 GREEN GREEN RED RED RED/GREEN RED/GREEN Startup - Initial test ON ON ON ON ON ON Waiting for configuration from EPB ON blinking OFF OFF OFF OFF Received configuration from EPB ON ON OFF OFF see the modules tables Table 5 - Initial / Dynamic signals LED OPR MODULE 485EPFCO LED ERR STATUS INDICATION DESCRIPTION STATUS INDICATION DESCRIPTION GREEN OPERATIONAL OPERATIONAL status OFF - Normal operation GREEN blinking slow GREEN 1 flash GREEN blinking fast PRE- OPERATIONAL STOPPED Autobaud PRE-OPERATIONAL status STOPPED status Baudrate detection RED 1 flash RED blinking fast RED 2 flashes Warning level LSS Event Control A bus error counter has reached the warning level LSS service operative RED EXCEPTION EXCEPTION status RED Lack of BUS BUS not working Table 6 Detected Node Guarding (NMT master or slave) or Heartbeat (Consumer) 8

LED NET MODULE 485EPFDN LED STS STATUS INDICATION DESCRIPTION STATUS INDICATION DESCRIPTION GREEN GREEN blinking (1Hz) RED RED blinking (1Hz) GREEN/RED alternate On-line connected On-line not connected Critical connection error Time-out of 1 or more connection TEST 1 or more connections established No connection established 485EPFDN unable to communicate One or more I/O device in time-out 485EPFDN in Test GREEN - Normal operation GREEN blinking (1Hz) RED RED blinking (1Hz) GREEN/RED alternate Table 7 Pending Fatal error Error TEST Configuration incomplete, 485EPFDN waiting for activation One or more unrecoverable errors detected One or more recoverable errors detected 485EPFDN in Test LED MODE MODULE 485EPFPD LED STS STATUS INDICATION DESCRIPTION STATUS INDICATION DESCRIPTION GREEN On-line data exchange OFF GREEN blinking RED blinking (1 flash) RED blinking (2 flashes) MBP not initialized STATUS SETUP o NW_INIT On-line CLEAR GREEN Initialized End of initialization NW_INIT Parameterization error PROFIBUS configuration error rif. IEC 61158-6 configuration data MASTER or MBP wrong GREEN blinking Initialized with diagnostic active EXTENDED DIAGNOSTIC bit set RED Exception error EXCEPTION STATUS Table 8 STS LED MODULE 485EPFEC ERR LED STATE INDICATION DESCRIPTION STATE INDICATION DESCRIPTION OFF INIT INIT or no power OFF No error No error or no power Green Flashes green Flashes green once OPERATIONAL PRE- OPERATIONAL SAFE- OPERATIONAL OPERATIONAL state PRE- OPERATIONAL state SAFE- OPERATIONAL state Flashes red Flashes red twice Configuration not valid Watchdog timeout Red (Fatal Event) System locked - - - Status change requested by master not possible Synch manager watchdog timeout Red Controller fault Anybus module in EXCEPTION state Table 9 9

NET LED MODULE 485EPFEI STS LED STATE INDICATION/DESCRIPTION STATE INDICATION DESCRIPTION OFF No power or no IP address OFF No power - Green On-line, connected Green RUN state - Flashes green On-line, not connected Flashes green Not configured - Red Duplicate IP address Red Fatal error One or more irremediable errors detected Flashes red Connection timeout Flashes red Error One or more remediable errors detected Table 10 NET LED MODULE 485EPFPN STS LED STATE INDICATION DESCRIPTION STATE INDICATION DESCRIPTION OFF Green Flashes green Offline Online (Run) Online (stop) No power Connection with IO controller not present Established connection with IO controller IO controller in RUN state Established connection with IO Controller IO Controller in STOP state OFF Green Flashes green once Flashes green twice Not initialised Normal operation Diagnostic event (i) Blink Used to identify the network node Red Exception Module in EXCEPTION state Flashes red once Configuration error Identification error Flashes red twice IP address error IP address not configured Flashes red 3 times Flashes red 4 times Table 11 Station name error Internal error Station name not configured MODULE 485EPFUB LED CONNECT STATE INDICATION DESCRIPTION Green USB connected Module connected to Pc via USB OFF USB not connected Module not connected Table 12 10

FAULT DIAGNOSIS LED MEANING ON RUN IN FAIL EXT FAIL LED1 LED2 GREEN GREEN RED RED RED/GREEN RED/GREEN Internal fault microcontroller ON OFF 2 flashes* OFF Internal board fault ON OFF 3 flashes* OFF Configuration Error ON OFF 5 flashes* OFF BUS communication error ON OFF 5 flashes* OFF see the tables of the individual modules BUS communication interruption ON OFF ON OFF Detected an identical module ON OFF 5 flashes* 5 flashes Table 13 * The LED frequency of flashing is: ON for 300ms and OFF for 400ms, with an interval between two sequences of 1s. 11

EXAMPLES OF DIAGNOSTICS Example 1 In the example shown in Figure 3, Input 1 (connected to module 485 EPB) is tested with the 485EPB -T1 test signal. During wiring, the 24Vdc is connected to input 1 instead of the 485EPB -T1 test signal. - The I/O index and diagnostics code fields assume the following values: 1-20 to indicate the diagnostics on input 1 of module 485EPB (Connection error). Figure 3 Example 2 In this example, the I/O index corresponds to the logical block and not to the physical terminal on module 485EPB. In Figure 4 for example, the two-hand element connected to the physical terminals Input 1 and Input 2 corresponds to I/O index No. 1 and the emergency stop connected to the terminals Input 3 and Input 4 corresponds to I/O index No. 2. index I/O n 1 index I/O n 2 Figure 4 12

Example 3 The example in Figure 5 is similar to example 1, except that in this case Input1 is connected to module 485EPE16 and is tested with the 485EPE16-T1 test signal. During wiring, the 24Vdc is connected to input 1 instead of the 485EPE16-T1 test signal. Input 1 has diagnostic code 10 (OUT_TEST error) and OUT_TEST MI16-T1 has diagnostic code 8 (Connection error). - The I/O index and Diagnostics code fields assume the following values: 1-20 to indicate the diagnostics on input 1 of module 485EPE16. Figure 5 In the example shown in Figure 6 the manual reset function is enabled on OSSD 1. The pushbutton connected to input 1 is pressed without sending a reset command. - The I/O index and diagnostics code fields assume the following values: 192-2 - to indicate the diagnostics on OSSD 1A/1B (Table 2: 192 = first output). - to indicate the diagnostics code (Table 4: 2 = Waiting for OSSD to restart). Figure 6 13

BUS CONFIGURATOR USER INTERFACE The bus module is configured using the micro USB interface on the front panel and the BUS CONFIGURATOR SW installed on the CD ROM disk of the configuration software. This SW can be used for configuration/communication of the eloprog system with a PC (using a 485EPFUB module) or to display data transmitted via bus (via connection to the USB port of a bus module). The diagram below is helpful for understanding possible connections: EXAMPLES OF CONNECTION 485EPFx <-> PLC elobau elobau 485EPFx <-> Pc 485EPFUB <-> Pc eloprog eloprog eloprog eloprog 485EPB 485EPFx (bus) 485EPB 485EPFUB (USB) It is important to note that the BUS CONFIGURATOR behaves differently, depending on whether there is a communication with a 485EPFx module or a 485EPFUB module: 485EPFx MODULE: THE SOFTWARE ONLY ALLOWS DATA TRANSMITTED VIA BUS TO BE DISPLAYED. 485EPFUB MODULE: THE SOFTWARE ALLOWS TWO-WAY DATA TRANSMISSION 485EPFUB PC (in this case the programmer can set the field bus input directly via computer). The data sets to be transmitted, any modular I/Os, the field bus inputs, the address of the module in the field bus network and the baud rate, if planned, are all settable parameters. The address field range depends on the type of field bus that is installed. 14

Graphic interface è Module configuration must be performed with the system switched off (outputs OFF). 485EPB Status You can query the module configuration at any time while the module is in use. To configure the 485EPFx module, proceed as follows: 1. connect the module to the 24VDC+20% power supply via the terminal block; 2. connect the USB cable to the PC and to the 485EPFx (or 485EPFUB) module; 3. click on the "BUS CONFIGURATOR USER INTERFACE" desktop icon. The configuration window shown at the side is displayed (Figure 7). 4. Press the CONNECT key. The program recognizes that a bus module is connected (Figure 8); the field bus model, the firmware version and the Master 485EPB status are displayed: green=485epb active (RUN); red=485epb not active (e.g. communication with the configuration software). Figure 7 Figure 8 485EPB Status 15

CONFIGURATION Once the module is connected it is recognized and you can configure the parameters by selecting the different cards shown in figures 9 to 12 (CONFIG key figure 7; press the WRITE-button to send the configuration data to the module. 485EPB Status 485 EPB Status Figure 9 - I/O selection Figure 10 - Address Figure 11 - Baud rate 485 EPB Status ADDRESS BAUD RATE 485EPFCO 127 AUTO 485EPFDN 63 AUTO 485EPFPD 126 N/A 485EPFEC 0 N/A 485EPFEI 0.0.0.0 AUTO 485EPFPN 0.0.0.0 N/A Table 14 - Default values INFORMATION SETS Input status Field bus input status Probe status Output status Input status Input status; Probe status Output status Input status Field bus input status Probe status Output status Input status Field bus input status Probe status Output status Input status Field bus input status Probe status Output status. Input status Field bus input status Probe status Output status 16

After setting the parameters, click on the MONITOR" key. As soon as the bus module receives the data, the configurator enters the dynamic status screen condition. The input and output status and relative diagnostics (displayed cyclically if one or more incorrect events occur) are illustrated in Figure 12 and Figure 13. The field bus inputs whose logical status can be changed freely by the programmer (with the 485EPFUB module only) or via the field bus are illustrated in Figure 14. Input/output status Input/output diagnostics Field bus input (485EPFUB only) Figure 14 Figure 13 Figure 12 PLEASE REFER TO THE EXAMPLE IN FIGURE 15 AND FIGURE 16 SHOWING A PROJECT CREATED BY USING THE CONFIGURATION SOFTWARE AND HOW THIS IS PRESENTED BY THE CONFIGURATOR. IN THIS WAY IT IS POSSIBLE TO COMPREHEND HOW THE PARAMETERS ARE SHOWN. 17

Example of configuration 2 1 3 4 1 2 5 3 Figure 15 Example of project 18

5 4 485EPB Status 1 2 3 Input 1 ENABLE is connected to terminal 24 on 485EPB. Its status (zero or one) is shown on bit 7 of byte 0 reserved for inputs. Input 2 MOD-SEL is connected to the terminals 17 and 18 on 485EPE08A02 with diagnostics indicating Mod-sel disconnected. Its status is shown on the pair of bits 0 and 1 of byte 1 reserved for inputs. Diagnostics are shown in the section reserved for input diagnostics with the index field showing 2 and the relative diagnostics. The probes on bit 6 and bit 8 are green and the relative bits on the screen are checked. Bit 8 is shown as bit 0 of the second byte. OSSD 1 is ON and connected to the second pair of 485EPB outputs. Its status is shown on bit 1 of byte 0 reserved for outputs. OSSD 2 is OFF with diagnostics indicating the waiting for Restart. Furthermore it is connected to the second pair of outputs of the 485EPE08A02. Its status is shown on bit 3 of byte 0 reserved for outputs. Diagnostics are shown in the section reserved for OSSD diagnostics with the index field showing 2 and the relative diagnostics. In the Virtual Input section, bit 0 has been selected and consequently the field bus input bit 0 in the project on the configuration software is green. Figure 16 19